Apparatus for maceration of meat

ABSTRACT

An apparatus is provided for macerating meat to effect deep penetration of the meat at multiple muscle height levels for improved absorption of curing agents and improved bonding of multiple pieces of meat. The method involves feeding the meat into a compression zone where it is compressed and simultaneously engaged with multi-level maceration means which penetrate and tear the meat at two or more muscle height levels below the surface of the meat; continuously feeding the meat through the compression zone; continuously compressing and macerating the meat at multiple muscle height levels; and expelling the meat from the compression zone to allow the meat to expand to its previous dimensions so that multi-level macerated surfaces are available for bonding of the meat. The apparatus includes a macerating unit or assembly in the form of a plurality of radially slotted discs mounted on a rotatable shaft including at least a first group of such discs in combination with a second group of radially slotted discs having a diameter less than the diameter of said first group and spaced between said first discs. The macerating assembly in combination with a meat macerating apparatus is used to carry out the method of the invention. The macerated meat product produced by the method has a surface containing deeply penetrating ruptures, tears and serrations extending into two or more muscle height levels at varying depths below the surface of the meat.

The present invention relates generally to a method and apparatus formacerating meat at multiple muscle height levels to achieve improvedabsorption of curing agents and improved bonding of two or more piecesof meat. Specifically, the invention relates to a method and to a systemof apparatus for maceration of meat by tearing, slitting, and rupturingthe protein fiber tissue at different muscle height levels, as achievedby an improved macerating unit characterized by a plurality of bluntedged radially slotted discs of differing diameters mounted on arotating shaft. The present invention is also directed to the productproduced by the multi-level maceration method.

Meat, whether it be poultry, pork or beef, can be macerated, byrupturing or tearing the protein fiber tissue, for the purpose ofreleasing myosin, actin and tropomyosin proteins. The release of theseproteins by maceration is desired in the bonding process whereby piecesof macerated meat can be physically pressed together and then molded andcooked under pressure, for example, as disclosed in our U.S. Pat. No.3,644,125 (issued Feb. 22, 1972). Due to the release of proteins bymaceration, the meat pieces can be joined together with a cohesion andbinding strength which is very close to that of the uncut meat cells ina whole piece of the same meat. A high degree of cohesion and bind isdesired in order to create a denser meat product which has theappearance of a single piece of meat and will remain firmly bondedtogether when sliced.

Meat is also macerated to allow for more complete and rapid curing.Maceration of the meat aids the curing process by increasing the surfacearea of the meat, thus allowing the curing agents to more thoroughly andrapidly penetrate the meat. Maceration also allows the curing agent topenetrate deeply into the innermost portions of the meat. The morethoroughly the curing agents penetrate, the better the preservative orstabilizing effect of the curing process on the protein. Without suchcuring, the protein may soon deteriorate and become unusable andunpalatable. Meat is also slit, ruptured or torn to produce, forexample, cube steak, or to tenderize pieces of meat.

Known devices for slitting or macerating meat include rotary knives orblades mounted on a common shaft above a meat-supporting table, alongwhich pieces of meat are slid beneath the rotating knives or blades formaceration. Other devices include a pair of opposing rotary blade shaftsthrough which the meat passes and is thereby macerated on both sides.However, these known devices are not capable of macerating more than onelevel of muscle tissue.

The multi-level maceration accomplished by the present invention is anew concept which provides for penetration and tearing at two or morelevels of muscle tissue. This multi-level maceration allows for a muchgreater release of myosin, actin and tropomyosin protein than the knownmethods or machines can accomplish. Thus, the degree of bonding andcohesion between multiple pieces of the multi-level macerated meat sgreatly increased, producing a much denser and cohesive meat product.Consequently, the meat has the appearance and texture of a whole pieceof meat making it more palatable and less likely to break into pieceswhen sliced than meat produced by the known methods and machines.Furthermore, the present invention allows for much more thoroughpenetration of the curing agents than the known methods or devices,because the mult-level penetration of muscle tissue increases the amountof surface area which is exposed to the curing agents.

It is therefore an object of the present invention to provide animprovement over known macerating methods and machines by providing forsimultaneous maceration of different muscle height levels found in meatto achieve faster and more complete maceration of the meat.

Another object of the present invention is to provide a multi-levelmaceration method which will improve the cohesion and binding ofmacerated pieces of meat which have been pressed together and cookedunder pressure, by rupturing and tearing more protein fiber tissuefaster thereby releasing more myosin, actin and tropomyosin protein.

Another object of the present invention is to provide a multi-levelmaceration method which will improve the curing process of meats byexposing more protein fiber tissue surface area to the curing agentsenabling deeper and more complete penetration by the curing agents.

It is a further object of the present invention to reduce energy usagein cooking or smoking by providing a multi-level maceration method whichwill expose more surface area of the meat causing increased pickledistribution and increased reabsorption and retention of myosin proteinresulting in a denser product which will cook and smoke faster. Energycosts will also be reduced because the increased degree of macerationwill reduce the tumbling, massaging or mixing time usually required inthe preparation of cured or smoked meat.

A further object of the present invention is to provide a multilevelmaceration method which will produce a meat product which is morepliable, resulting in better conforming in the pressing process and thereduction of voids in the final meat product.

It is another object of the present invention to provide an improvedsystem of apparatus for accomplishing the multi-level maceration method,including an improved multi-level maceration unit.

It is a further object of the present invention to provide a denser,more cohesive and more palatable meat product that has the appearance ofone piece of meat after the macerated meat pieces have been pressed andbonded together.

In general, the present invention consists of an improved method andapparatus for macerating meat to effect deep penetration and tearing ofthe meat at multiple muscle height levels to improve and increaseabsorption of curing agents and the degree of bonding and cohesionbetween multiple pieces of meat. The method involves feeding the meatinto a compression zone, continuously and progressively compressing themeat, simultaneously penetrating and tearing the meat at two or moremuscle height levels while it is compressed and fed through thecompression zone, and expelling the meat from the compression zoneallowing it to expand to its previous dimensions before it undergoesfurther treatment, such as exposure to curing agents or bonding.

Preferably, the multi-level penetration and tearing is accomplished bymeans of a multi-level maceration unit or assembly according to thepresent invention, which consists of a plurality of blunt edged radiallyslotted discs of differing diameters mounted on a rotating shaft. Thepresent invention also contemplates a meat macerating apparatus whichincludes such macerating assembly and the macerated meat productresulting from the new multi-level maceration method.

Additional objects and features of the invention will be evident fromthe following description taken in conjunction with the accompanyingdrawings.

FIG. 1 is a flow sheet illustrating the steps in the method of thepresent invention.

FIGS. 2-5 are schematic views in cross section of the meat as itprogresses through the steps in the method of the invention, and of themacerating assembly of the invention as it is employed in the method.

FIG. 6 is a schematic view in plan of the meat product produced by themethod of the invention.

FIGS. 7-9 are schematic views in cross section of the meat productproduced by the method of the invention.

FIG. 10 is a schematic view in cross section, representative of themanner in which two pieces of meat which have been macerated accordingto the method of the invention would be bonded together in the pressingand cooking process.

FIG. 11 is an illustration of one preferred embodiment of a maceratingunit or assembly according to the present invention.

FIGS. 12, 13, and 14 represent such macerating assembly in combinationwith differing embodiments of meat macerating machines according to thepresent invention.

Referring to FIG. 1, the method for macerating meat at multiple muscleheight levels is illustrated. The piece of meat to be macerated is fedinto a compression zone in step 10. The meat is compressed in thecompression zone, step 12, and simultaneously engaged by a multi-levelmaceration means which deeply penetrates one level of muscle tissuebelow the surface of a portion of the meat, step 14. Another portion ofthe meat is simultaneously engaged and penetrated by the multi-levelmaceration means at a different muscle tissue level in step 16.Throughout steps 12, 14, and 16 the meat is being fed through thecompression zone causing the meat to be torn and ruptured at differingpoints and depths of penetration by the multi-level maceration means. Asthe meat is fed through the compression zone it is continuously andprogressively compressed, penetrated and torn until it is expelled fromthe compression zone in step 18. In step 20, after the meat is expelled,it is allowed to expand to its previous dimensions resulting inmacerated meat product A. The penetrations and tears which occurredwhile the meat was compressed become deeper as the meat expands andextend far into the interior of the meat at different muscle heightlevels. While the method diagrammed in FIG. 1 relates to penetration andtearing of the meat at at least two different muscle height levels, thebroad method includes the simultaneous penetration of the meat at threeor even more muscle height levels. As noted hereinafter, the method ofthe present invention also contemplates further processing where two ormore exterior surfaces of the meat are simultaneously penetrated andtorn at at least two, or more, muscle heignt levels.

Referring again to FIG. 1, additional steps are shown for furthertreatment of the intermediate meat product A. In step 30, two or morepieces of the macerated meat are placed together so that the maceratedsurface of one piece is in contact with the macerated surface of theother piece. The pieces of meat are then pressed together in acompression mold in step 32. Subsequently the pressed and molded meat iscooked under pressure in step 34, resulting in the cooked meat productB. This pressing and cooking process is disclosed in our U.S. Pat. No.3,644,125.

The resulting product B represents a great improvement over priorproducts due to the multi-level maceration method of the presentinvention. By subjecting two or more levels of muscle tissue tomaceration as opposed to the known method of single level maceration,much more myosin, actin and tropomyosin protein is released. As aresults, when the macerated surfaces are pressed together and cooked,the released proteins join together to create new muscle tissue betweenthe macerated surfaces of the original muscle tissue, serving to bondthe pieces of meat together with a much greater degree of cohesion thanwas made possible by the known method of single muscle level maceration.

There will also be a much improved distribution and absorption of thecuring agents due to the exposure to an increased amount of the meat'ssurface area.

FIGS. 2-5 are schematic drawings which illustrate one preferredembodiment of the method of the present invention. FIG. 2 shows the meatprior to its entry into the compression zone 40, located just below themulti-level maceration means 42 and where the meat is subjected tocompression. The multi-level maceration means 42 as shown in FIGS. 2-5consists of a plurality of blunt edged radially slotted discs ofdifferent diameters. The discs are mounted on a rotating shaft in analternating pattern so that discs of smaller diameter 44 alternate withthe discs of larger diameter 46.

FIG. 3 illustrates the passage of the meat through the compression zone,where it is simultaneously compressed and penetrated by the slotteddiscs. The smaller discs compress and penetrate one portion of the meatat one level of muscle tissue while the larger discs simultaneouslycompress and penetrate another portion of the meat at a second muscletissue level. The blunt edges of the slotted discs engage and penetratethe meat as it enters the compression zone and the rotating action ofthe discs serves to macerate or tear the meat and continuously feed themeat into and through the compression zone. Specifically, the rotatingaction of the discs causes the meat to be punctured, ruptured and tornat the points where the blunt edges of the slotted discs have penetratedthe muscle tissue, and to be slit along rough serrated lines 45 and 47generally interconnecting the penetration points (see FIG. 6). The tearsin the meat are initiated at the two penetration points 50 and 52 toachieve two levels of penetration 53 and 55 due to the maceration actionof the two sizes of discs 44 and 46.

FIG. 4 illustrates the meat as part of it leaves the compression zoneand the remaining part is simultaneously compressed, penetrated and tornby the slotted discs 44 and 46 as it is being fed through thecompression zone 40. After the meat is expelled from the compressionzone it begins to expand to its previous dimensions as seen in FIG. 4.

FIG. 5 illustrates the meat after it has been completely expelled fromthe compression zone 40. The meat has completely expanded to itsoriginal size and the tears extend deep into its interior at twodifferent levels 53 and 55. The macerated meat is now ready for furthertreatment in the pressing and cooking process.

FIG. 6 illustrates a plan view of the meat's surface after it has beenmacerated according to the method of the present invention. There arenumerous elongated punctures 63 extending deep into the meat and whichare interconnected by the slit line 45 and 47. The tears are the resultof the rotating action of the blunt edges of the slotted discs as theypenetrate and slit the meat.

FIG. 7 is a cross sectional view of the meat taken along the line 7--7of FIG. 6, and shows the penetrations and tears 64 effected by thesmaller slotted discs 44 (as shown in FIGS. 2-5) at the first level ofmuscle tissue 53 as they penetrate the meat and pull it further into thecompression zone. The broken lines illustrate the deeper penetrationsand tears, which are not visible in this view, effected by the largerslotted discs 46 (as shown in FIGS. 2-5) at the second level of muscletissue 55.

FIG. 8, a cross sectional view of the meat taken along the line of 8--8from FIG. 6 illustrates the deeper penetrations and tears 65 made by theblunt edges of the larger slotted discs 46 as they penetrate and slicethe meat at a second muscle height level 55 and pull it further into thecompression zone. The broken lines represent the penetrations and tears64, which are not visible in this view, made by the smaller discs 44 atthe first muscle height level 53.

FIG. 9 represents a cross sectional view of the meat taken along theline 9--9 where in the penetrations and tears 64 and 65 at the twomuscle height levels are visible.

FIG. 10 is a cross sectional view of two pieces of meat with theirmacerated surfaces in contact and pressed together. In the pressing ofthe meat the macerated surfaces generally conform to one another so thatthe meat surface of one piece moves and conforms into the penetrationsand tears of the other piece. As the meat is pressed and molded togetherand cooked under pressure, the macerated surfaces bond togethereliminating gaps, as represented schematically at 66.

The method of the present invention improves the bonding of the meatbecause the multi-level maceration releases more of the proteins whichare responsible for the bonding than known maceration methods, andbecause bonding takes place at mutiple levels as opposed to a singlelevel of bonding achieved in prior maceration methods. The improvedbonding achieved by multi-level maceration results in a denser and morecohesive final meat product. The denser product will cook faster, bemore likely to remain in one piece when sliced, have a much more tenderbite and be more palatable. Further, the multi-level maceration producesmore pliable intermediate meat pieces which conform better in thepressing process thus reducing voids in the meat.

Referring to FIG. 11, one preferred embodiment of the maceratingassembly of the present invention comprises a shaft 71 with a pluralityof blunt edged radially slotted discs of differing diameters 72 and 73mounted thereon. The discs of larger diameter 72 alternate with thediscs of smaller diameter 73, so that meat passing into contact with thediscs is simultaneously macerated at two different muscle height levels.Both sets of discs have blunted radial and peripheral edges so that themeat is ruptured and torn as well as serrated and slit. The shaft 71includes means 74 for mounting said shaft for rotation.

The present invention contemplates the macerating assembly incombination with various types or assemblies of meat maceratingapparatus. Referring to FIG. 12, one embodiment of a macerating unit orassembly 75 is shown in a meat macerating machine comprising an inclinedmeat-supporting table 76 and a pressure device 77. The meat slides alongthe inclined table until it passes under the rotating maceratingassembly 75 where it is ruptured and torn by the radially slotted discsof two different diameters. The pressure device 77 can be adjusted so asto project the inclined table and the meat upward toward the discs. Thisallows the machine to accommodate smaller sizes of meat or to achieve agreater degree of compression.

Referring to FIG. 13, there is illustrated two macerating units orassemblies 78 and 79 in a meat macerating machine where the meat passesbetween two contra-rotating shafts 80 and 81 of macerating discs and issimultaneously macerated on two sides at two different muscle heightlevels.

Referring to FIG. 14, there is illustrated a macerating assembly 82 in ameat macerating machine which consists of a smooth roller 83 mounted ona second rotatable shaft 84 opposite the rotatable shaft 85 with themacerating discs. The meat passes between the contra-rotating shafts 84and 84 and is macerated at two different muscle height levels on oneside of the meat while the smooth roller helps to urge the meat throughthe machine as well as to compress the meat.

The method and apparatus of the present invention provide the commercialmeat processor with many useful and unexpected advantages. For instance,the multi-level maceration of meat improves the cohesion and binding ofpieces of macerated meat that are pressed together and cooked underpressure, a denser meat product results which cooks or smokes faster,and thus reduces energy usage in the cooking or smoking process.Furthermore, the meat processor can sell his meat product with moreconfidence as to consumer satisfaction because the multi-levelmaceration can produce a final meat product which after the bonding andcooking process has the appearance of a single piece of meat, remains inone piece when sliced, and is more palatable.

What is claimed is:
 1. A macerating assembly for macerating meatcomprising:a shaft, a plurality of first discs mounted on said shaft, aplurality of second discs with a diameter less than the diameter of saidfirst discs mounted on said shaft and spaced between said first discs,said first and second discs having radial slots in their peripherypresenting radial and peripheral blunt edges for simultaneouslycompressing and macerating meat at multiple muscle height levels, saidsecond discs extending radially to a distance such that their peripheraledges are at the deepest point of said slots in said first discs, saidsecond discs thereby serving to simultaneously compress and maceratesaid meat at a different muscle height level than said second discs. 2.An apparatus for macerating meat comprising:a macerating assemblyaccording to claim 1, wherein said shaft is mounted for rotation, meansfor driving said shaft, and means for urging the meat toward and intocontact with said macerating assembly whereby the meat is macerated. 3.An apparatus for macerating meat according to claim 2, wherein saidmeans for urging the meat toward and into contact with said maceratingassembly comprises:an inclined meat-supporting table.
 4. An apparatusfor macerating meat according to claim 3, together with a pressuredevice for adjusting the upward projection of the meat toward and awayfrom said macerating assembly.
 5. An apparatus for macerating meatcomprising:a first macerating assembly according to claim 1 wherein saidshaft is mounted for rotation, a second macerating assembly according toclaim 1 wherein said shaft is mounted for rotation contra to therotation of said first shaft and spaced apart from said first shaft todefine a plane therebetween through which pieces of meat pass intocontact with said macerating assembly and are macerated, and means fordriving said shafts.
 6. An apparatus for macerating meat according toclaim 5, wherein one of said shafts is adjustably mounted to vary thedistance between said shafts.
 7. An apparatus for macerating meataccording to claim 5, wherein said means drives the shafts at differentrelative speeds.
 8. An apparatus for macerating meat comprising:a firstmacerating assembly according to claim 1 wherei said shaft is mountedfor rotation, a second shaft mounted for rotation contra to the rotationof said first shaft and spaced apart from said first shaft to define aplane therebetween, and a smooth roller mounted on said second shaft forfeeding the meat, compressing the meat and urging the meat into contactwith said macerating assembly whereby the meat is macerated.
 9. Anapparatus for macerating meat according to claim 8, wherein one of saidshafts is movably mounted for varying the distance between said shafts.